Biaxial Residual Stress Mapping for a Dissimilar Metal Welded Nozzle

This paper describes a sequence of residual stress measurements made to determine a two-dimensional map of biaxial residual stress in a nozzle mockup having two welds, one a dissimilar metal (DM) weld and the other a stainless steel (SS) weld. The mockup is cylindrical, designed to represent a pressurizer surge nozzle of a nuclear pressurized water reactor (PWR), and was fabricated for Phase 2a of the NRC/EPRI welding residual stress round robin. The mockup has a nickel alloy DM weld joining a SS safe end to a low-alloy steel cylinder and stiffening ring, as well as a SS weld joining the safe end to a section of pipe. The biaxial mapping experiments follow the approach described earlier, in PVP2012-78885 and PVP2013-97246, and comprise a series of experimental steps and a computation to determine a two-dimensional map of biaxial (axial and hoop) residual stress near the SS and DM welds. Specifically, the biaxial stresses are a combination of a contour measurement of hoop stress in the cylinder, slitting measurements of axial stress in thin slices removed from the cylinder wall, and a computation that determines the axial stress induced by measured hoop stress. At the DM weld, hoop stress is tensile near the OD (240 MPa) and compressive at the ID (−320 MPa), and axial stress is tensile near the OD (370 MPa) and compressive near the mid-thickness (−230 MPa) and ID (−250 MPa). At the SS weld, hoop stress is tensile near the OD (330 MPa) and compressive near the ID (−210 MPa), and axial stress is tensile at the OD (220 MPa) and compressive near mid-thickness (−225 MPa) and ID (−30 MPa). The measured stresses are found to be consistent with earlier work in similar configurations.